Instructions-Parts Python XL Chemical Injection

3A4019HEN

Instructions-Parts

Python® XL Chemical Injection PumpPneumatic pump for injecting chemicals at well sites. For use with compressed air only. For professional use only.

See page 3 for model information, including maximum working pressures.

Important Safety InstructionsRead all warnings and instructions in this manual. Save all instructions.

II 2 G Ex h T6 Gb

2 3A4019H

ContentsModels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Configuration Number Matrix . . . . . . . . . . . . . . . . . 4

Pump Configuration . . . . . . . . . . . . . . . . . . . . . . 4Lower Configuration . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 5Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Required Accessories . . . . . . . . . . . . . . . . . . . . . 7Flush Before Using Equipment . . . . . . . . . . . . . . 7Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 8Mount the Pump and Connect Chemical Supply 8Connect Pneumatic Supply . . . . . . . . . . . . . . . . . 9Connect Chemical Outlet . . . . . . . . . . . . . . . . . . 9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Pressure Relief Procedure . . . . . . . . . . . . . . . . 13Flush the Equipment . . . . . . . . . . . . . . . . . . . . . 13Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . 14Calibrate Chemical Dosage . . . . . . . . . . . . . . . 14

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Preventive Maintenance Schedule . . . . . . . . . . 18Tighten Threaded Connections . . . . . . . . . . . . . 18Tighten Packings . . . . . . . . . . . . . . . . . . . . . . . 18Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 19Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 24Pneumatic Valve . . . . . . . . . . . . . . . . . . . . . . . . 26Replace Pilot Valves . . . . . . . . . . . . . . . . . . . . . 28Disconnect the Pneumatic Motor . . . . . . . . . . . 29Reconnect the Pneumatic Motor . . . . . . . . . . . . 29Repair Pneumatic Motor . . . . . . . . . . . . . . . . . . 30

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Python XL Pneumatic Pump . . . . . . . . . . . . . . . 33Pneumatic Motor Parts . . . . . . . . . . . . . . . . . . . 37Pneumatic Motor Parts . . . . . . . . . . . . . . . . . . . 38Pneumatic Valve Parts . . . . . . . . . . . . . . . . . . . 39

Kits and Accessories . . . . . . . . . . . . . . . . . . . . . . 41

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Python XL Pump Dimensions . . . . . . . . . . . . . . 42Wall Bracket Mounting Hole Diagram, 2.5 in. & 3.5

in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Wall Bracket Mounting Hole Diagram, 4.5 in. . . 43Performance Charts . . . . . . . . . . . . . . . . . . . . . 442.5 in. Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 443.5 in. Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 474.5 in. Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Air/Gas Consumption . . . . . . . . . . . . . . . . . . . . 53

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54California Proposition 65 . . . . . . . . . . . . . . . . . . . 55Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 56

Models

3A4019H 3

Models

NOTE: See the Configuration Number Matrix, page 4, to find the plunger and pneumatic motor size for your unit.

Plunger SizePneumatic Motor Size

Maximum Working Pressurepsi (MPa, bar)

Maximum Pneumatic Inlet Pressurepsi (MPa, bar)

1/8 in.

2.5 in.

12,000 (82.7, 827.4) 30.0 (0.2, 2.1)

3/16 in. 12,000 (82.7, 827.4) 67.5 (0.5, 4.7)

1/4 in. 10,000 (68.9, 689.5) 100 (0.69, 6.9)

3/8 in. 4444 (27.6, 275.8)

1/2 in. 2500 (17.2, 172.4)

5/8 in. 1600 (11.0, 110.3)

3/4 in. 1111 (7.7, 76.6)

1/4 in.

3.5 in.

12,000 (82.7, 827) 61.2 (0.4, 4.2)

3/8 in. 8700 (60.0, 599.8)

100 (0.69, 6.9)1/2 in. 4900 (33.8, 337.8)

5/8 in. 3136 (21.6, 216.2)

3/4 in. 2180 (15.0, 150.3)

1/4 in.

4.5 in.

12,000 (82.7, 822.4) 37.0 (0.3, 2.6)

3/8 in. 10,000 (68.9, 689.5) 69.4 (0.5, 4.8)

1/2 in. 8100 (55.8, 558.5) 100 (0.69, 6.9)

5/8 in. 5200 (35.9, 358.5)

3/4 in. 3600 (24.8, 248.2)

Configuration Number Matrix

4 3A4019H

Configuration Number MatrixCheck the identification plate (ID) for the 12-digit Configuration Number of your pump. Use the following matrix to define the components of your pump.

NOTE: Not all combinations are possible.

Sample Configuration Number: PCI-350-25S-XA-A

Pump Configuration

Key Points

• All pumps feature 1/4 in. NPT(F) inlet connections.

• Kit B32240 can be used to convert an HF4 outlet connection to a 1/4 in. NPT(F) for applications at or under 10,000 psi.

Lower Configuration

PCI 350 25 S X A A

Pneumatic Chemical Injection

Pneumatic Motor Size

Plunger Size Pressure Range Plunger Material Seal Material Qualifier

Pneumatic Motor Size Plunger Size

Outlet Connection Type Plunger Material

Seal Material Qualifier

250 2 1/2 in. 13 1/8 in. diameter S 1/4 in. NPT(F) X Chromex A FKM A ATEX350 3 1/2 in. 19 3/16 in. diameter H HiP HF4 C Ceramic B FKMETP450 4 1/2 in. 25 1/4 in. diameter C HNBR

38 3/8 in. diameter D FFKM50 1/2 in. diameter E TFE/P63 5/8 in. diameter75 3/4 in. diameter

Plunger SizeOutlet Connection

Type Plunger MaterialSeal

Material13 1/8 in. diameter S 1/4 in. NPT(F) X Chromex A FKM19 3/16 in. diameter H HiP HF4 C Ceramic B FKMETP25 1/4 in. diameter C HNBR38 3/8 in. diameter D FFKM50 1/2 in. diameter E TFE/P63 5/8 in. diameter75 3/4 in. diameter

Warnings

3A4019H 5

WarningsThe following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

FIRE AND EXPLOSION HAZARDWhen flammable fluids are present in the work area be aware that flammable fumes can ignite or explode. To help prevent fire and explosion:• Use equipment only in well ventilated area.• Eliminate all ignition sources, such as cigarettes and portable electric lamps.• Ground all equipment in the work area.• Keep work area free of debris, including rags and spilled or open containers of solvent.• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.• Use only grounded hoses.• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until

you identify and correct the problem.• Keep a working fire extinguisher in the work area.SKIN INJECTION HAZARDHigh-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.• Do not put your hand over the fluid outlet.• Do not stop or deflect leaks with your hand, body, glove, or rag.• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or

servicing equipment. • Tighten all fluid connections before operating the equipment.• Check hoses and couplings daily. Replace worn or damaged parts immediately.

TOXIC FLUID OR FUMES HAZARDToxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.• Read Safety Data Sheet (SDS) to know the specific hazards of the fluids you are using.• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

Warnings

6 3A4019H

PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not limited to:• Protective eyewear, and hearing protection. • Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

EQUIPMENT MISUSE HAZARDMisuse can cause death or serious injury.• Do not operate the unit when fatigued or under the influence of drugs or alcohol.• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-

ponent. See Technical Data in all equipment manuals.• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheet (SDS) from distributor or retailer.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.• Check equipment regularly. Repair or replace worn or damaged parts immediately with genuine man-

ufacturer’s replacement parts only.• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create

safety hazards.• Make sure all equipment is rated and approved for the environment in which you are using it.• Use equipment only for its intended purpose. Call your distributor for information.• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.• Do not kink or over bend hoses or use hoses to pull equipment.• Keep children and animals away from work area.• Comply with all applicable safety regulations.

Installation

3A4019H 7

Installation

Grounding

Pump: ground through electrically conductive pneu-matic and fluid lines.

Pneumatic and fluid lines: use only electrically con-ductive lines.

Air compressor: follow manufacturer’s recommenda-tions.

Fluid supply container: follow local code.

Required AccessoriesInstall the following required accessories in the order shown in FIG. 1, using adapters as necessary. See Kits and Accessories starting on page 41.

Pneumatic Line

• Bleed-type master pneumatic valve (D): required in your system to relieve air/gas trapped between it and the pneumatic motor when the valve is closed.

• Be sure the valve is easily accessible from the pump and located downstream from the pneu-matic regulator.

• Pump pneumatic regulator (E): to control pump speed and outlet pressure. Locate it close to the pump.

• Pneumatic line filter (C): removes harmful dirt and moisture from compressed air/gas supply.

Fluid Line

• Fluid filter (Y-Strainer) (included in G): with a 60 mesh (250 micron) stainless steel element to filter particles from the fluid before in reaches the pump.

• Fluid shutoff valve (H): shuts off fluid flow.

• Pressure relief valve (J): overload protection.

Flush Before Using EquipmentThe equipment was tested with lightweight oil, which is left in the fluid passages to protect parts. To avoid con-taminating your fluid with oil, flush the equipment with a compatible solvent before using the equipment. See Flush the Equipment, page 13.

To reduce the risk of injury from ejected ice, do not operate the motor without a plumbed exhaust line or muffler installed.

Installation must comply with all local codes and regu-lations.

The equipment must be grounded to reduce the risk of static sparking. Static sparking can cause fumes to ignite or explode. Grounding provides an escape wire for the electric current.

Installation

8 3A4019H

Typical Installation

FIG. 1 is an example of an installation with a Python chemical injection pump. Your installation may differ from what is shown here. (See Required Accessories, page 7.) The Python pump (F) is the only component in FIG. 1 supplied by Graco. All other components are sup-plied by customer.

Key:A Main Pneumatic Supply LineB Pneumatic Needle ValveC Pneumatic FilterD Bleed-type Master Pneumatic ValveE Pneumatic Pressure RegulatorF PumpG Manifold Assembly (includes y-strainer and fluid shutoff

valve (H))H Fluid Shutoff Valve (inlet & outlet)J Fluid Pressure Relief ValveK Fluid Inlet LineL Inlet PortM Outlet PortN Pneumatic LubricatorP Fluid Outlet Line

Mount the Pump and Connect Chemical Supply

The pump can be used with supplied legs, or the pump stand can be bolted to a wall or skid by the attached bracket.

If you have an application, or mounting configuration, that requires installation in a manner different than depicted in FIG. 1, please contact your Graco distributor for assistance.

NOTE: A y-strainer (G) or chemical filter is required before the pump inlet. This will keep any debris from the tank from reaching the pump seals. Fluid filters are available from Graco. See Kits and Accessories on page 41.

1. Mount the pump (F) and connect the fluid inlet line (K).

FIG. 1: Typical Installation

A

C

ED

BF

J

K

H

G

L

M

NH

P

Installation

3A4019H 9

Connect Pneumatic Supply1. Install the pneumatic regulator (E) and gauge to

control the inlet pressure. See Models on page 3 for your model’s maximum pneumatic pressure.

NOTE: If less than 100 psi supply pressure is used, the pump’s maximum output pressure will be decreased proportionally. See Minimum Pneumatic Pressures by Fluid Plunger Size and Outlet Pressures on page 10. Minimum Pneumatic Pressure can be found by first find-ing the table that corresponds to the plunger size. Next, using the column that corresponds to the pneumatic motor size, find the row equal to or slightly greater than the outlet pressure of the pump. The value is the Mini-mum Pneumatic Pressure required to achieve the fluid outlet pressure.

2. Install a pneumatic line filter (C) to keep debris from affecting pump performance and to increase pump life.

NOTE: Keep the needle valve knob closed at this point to keep the pump from operating without fluid, which minimizes seal wear.

3. Attach a pneumatic line to the 1/4 in. female NPT port (116) on the needle valve.

NOTE: In some applications the air source may contain solvents that can breakdown the factory grease in the air motor. This may cause the air motor to stall. If the air motor stalls, then install an in-line pneumatic lubricator. See Kits and Accessories on page 40 for the recom-mended pneumatic lubricator.

Connect Chemical Outlet1. Connect a 1/4 npt(f) fluid line from the outlet check

valve (M) to the injection point.

NOTE: On “H” outlet connection configurations (PCI-xxx-xxH-xx-x), the 1/4 npt(f) fitting is replaced with an HiP HF4 fitting.

2. Install a fluid pressure relief valve (J) on the outlet side of the pump.

NOTE: A pressure relief valve is available from Graco and can be connected back to the tank or directly to the inlet side of the pump. See Kits and Accessories on page 41.

3. Set the pressure relief valve at or below the maxi-mum working pressure of the pump.

4. Connect a 10-32 UNF fluid outlet from the prime/bleed valve (21) to the fluid source or waste reservoir.

NOTE: On “H” outlet connection configurations (PCI-xxx-xxH-xx-x), the 10-32 fitting is replaced with a 1/16 in. NPT(F) fitting.

In the event of an injection line blockage, to reduce the risk of skin injection and damage to the pump, ensure the pressure relief valve is set at or below the maxi-mum working pressure of the pump.

Installation

10 3A4019H

Minimum Pneumatic Pressures by Fluid Plunger Size and Outlet PressuresActual running pressure must be set in field to avoid stalling. See Performance Charts, starting on page 44, for maximum flows at any given pressure.

250 Pneumatic Motor Minimum Gas Pressure psi (MPa, bar)

Outlet Pressure

psi (MPa, bar)

1/8 Inch

Fluid Plunger

3/16 Inch

Fluid Plunger

1/4 Inch

Fluid Plunger

3/8 Inch

Fluid Plunger

1/2 Inch

Fluid Plunger

5/8 Inch

Fluid Plunger

3/4 Inch

Fluid Plunger0 (0, 0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0)

250 (1.7, 17.2) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.6 (0.1, 1.1) 22.5 (0.2, 1.6)500 (3.4, 34.5) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 20.0 (0.1, 1.4) 31.3 (0.2, 2.2) 45.0 (0.3, 3.1)750 (5.2, 51.7) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 16.9 (0.1, 1.2) 30.0 (0.2, 2.1) 46.9 (0.3, 3.2) 67.5 (0.5, 4.7)

1000 (6.9, 68.9) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 22.5 (0.2, 1.6) 40.0 (0.3, 2.8) 62.5 (0.4, 4.3) 90.0 (0.6, 6.2)1111 (7.7, 76.6) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 25.0 (0.2, 1.7) 44.4 (0.3, 3.1) 69.4 (0.5, 4.8) 100.0 (0.7, 6.9)

1500 (10.3, 103.4) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 33.8 (0.2, 2.3) 60.0 (0.4, 4.1) 93.8 (0.6, 6.5)1600 (11.0, 110.3) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 16.0 (0.1, 1.1) 36.0 (0.2, 2.5) 64.0 (0.4, 4.4) 100.0 (0.7, 6.9)2000 (13.8, 137.9) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 20.0 (0.1, 1.4) 45.0 (0.3, 3.1) 80.0 (0.6, 5.5)2250 (15.5, 155.1) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 22.5 (0.2, 1.6) 50.6 (0.3, 3.5) 90.0 (0.6, 6.2)2500 (17.2, 172.4) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 25.0 (0.2, 1.7) 56.3 (0.4, 3.9) 100.0 (0.7, 6.9)2750 (19.0, 189.6) 15.0 (0.1, 1.0) 15.5 (0.1, 1.1) 27.5 (0.2, 1.9) 61.9 (0.4, 4.3)3000 (20.7, 206.8) 15.0 (0.1, 1.0) 16.9 (0.1, 1.2) 30.0 (0.2, 2.1) 67.5 (0.5, 4.7)3250 (22.4, 224.1) 15.0 (0.1, 1.0) 18.3 (0.1, 1.3) 32.5 (0.2, 2.2) 73.1 (0.5, 5.0)3500 (24.1, 241.3) 15.0 (0.1, 1.0) 19.7 (0.1, 1.4) 35.0 (0.2, 2.4) 78.8 (0.5, 5.4)3750 (25.9, 258.6) 15.0 (0.1, 1.0) 21.1 (0.1, 1.5) 37.5 (0.3, 2.6) 84.4 (0.6, 5.8)4000 (27.6, 275.8) 15.0 (0.1, 1.0) 22.5 (0.2, 1.6) 40.0 (0.3, 2.8) 90.0 (0.6, 6.2)4250 (29.3, 293.0) 15.0 (0.1, 1.0) 23.9 (0.2, 1.6) 42.5 (0.3, 2.9) 95.6 (0.7, 6.6)4444 (30.6, 306.4) 15.0 (0.1, 1.0) 25.0 (0.2, 1.7) 44.4 (0.3, 3.1) 100.0 (0.7, 6.9)4750 (32.8, 327.5) 15.0 (0.1, 1.0) 26.7 (0.2, 1.8) 47.5 (0.3, 3.3)5000 (34.5, 344.7) 15.0 (0.1, 1.0) 28.1 (0.2, 1.9) 50.0 (0.3, 3.4)5250 (36.2, 362.0) 15.0 (0.1, 1.0) 29.5 (0.2, 2.0) 52.5 (0.4, 3.6)5500 (37.9, 379.2) 15.0 (0.1, 1.0) 30.9 (0.2, 2.1) 55.0 (0.4, 3.8)5750 (39.6, 396.4) 15.0 (0.1, 1.0) 32.3 (0.2, 2.2) 57.5 (0.4, 4.0)6000 (41.4, 413.7) 15.0 (0.1, 1.0) 33.8 (0.2, 2.3) 60.0 (0.4, 4.1)6250 (43.1, 430.9) 15.6 (0.1, 1.1) 35.2 (0.2, 2.4) 62.5 (0.4, 4.3)6500 (44.8, 448.2) 16.3 (0.1, 1.1) 36.6 (0.3, 2.5) 65.0 (0.4, 4.5)6750 (46.5, 465.4) 16.9 (0.1, 1.2) 38.0 (0.3, 2.6) 67.5 (0.5, 4.7)7000 (48.3, 482.6) 17.5 (0.1, 1.2) 39.4 (0.3, 2.7) 70.0 (0.5, 4.8)7250 (50.0, 499.9) 18.1 (0.1, 1.2) 40.8 (0.3, 2.8) 72.5 (0.5, 5.0)7500 (51.7, 517.1) 18.8 (0.1, 1.3) 42.2 (0.3, 2.9) 75.0 (0.5, 5.2)7750 (53.4, 534.3) 19.4 (0.1, 1.3) 43.6 (0.3, 3.0) 77.5 (0.5, 5.3)8000 (55.2, 551.6) 20.0 (0.1, 1.4) 45.0 (0.3, 3.1) 80.0 (0.6, 5.5)8250 (56.9, 568.8) 20.6 (0.1, 1.4) 46.4 (0.3, 3.2) 82.5 (0.6, 5.7)8500 (58.6, 586.1) 21.3 (0.1, 1.5) 47.8 (0.3, 3.3) 85.0 (0.6, 5.9)8750 (60.3, 603.3) 21.9 (0.2, 1.5) 49.2 (0.3, 3.4) 87.5 (0.6, 6.0)9000 (62.1, 620.5) 22.5 (0.2, 1.6) 50.6 (0.3, 3.5) 90.0 (0.6, 6.2)9250 (63.8, 637.8) 23.1 (0.2, 1.6) 52.0 (0.4, 3.6) 92.5 (0.6, 6.4)9500 (65.5, 655.0) 23.8 (0.2, 1.6) 53.4 (0.4, 3.7) 95.0 (0.7, 6.6)9700 (66.9, 668.8) 24.3 (0.2, 1.7) 54.6 (0.4, 3.8) 97.0 (0.7, 6.7)

10000 (68.9, 689.5) 25.0 (0.2, 1.7) 56.3 (0.4, 3.9) 100.0 (0.7, 6.9)10250 (70.7, 706.7) 25.6 (0.2, 1.8) 57.7 (0.4, 4.0)10500 (72.4, 723.9) 26.3 (0.2, 1.8) 59.1 (0.4, 4.1)10750 (74.1, 741.2) 26.9 (0.2, 1.9) 60.5 (0.4, 4.2)11000 (75.8, 758.4) 27.5 (0.2, 1.9) 61.9 (0.4, 4.3)11250 (77.6, 775.7) 28.1 (0.2, 1.9) 63.3 (0.4, 4.4)11500 (79.3, 792.9) 28.8 (0.2, 2.0) 64.7 (0.4, 4.5)11750 (81.0, 810.1) 29.4 (0.2, 2.0) 66.1 (0.5, 4.6)12000 (82.7, 827.4) 30.0 (0.2, 2.1) 67.5 (0.5, 4.7)

For applications where the exhaust is ported to a pressurized location, compute the difference between the inlet and outlet pressures to get the pneumatic pressure to be used in the above tables. Minimum pressure differential is 15 psi (0.1 Mpa, 1.0 bar).

NOTE: Regardless of exhaust pressure, maxi-mum inlet pressure is 100 psi (0.7 MPa, 6.9 bar), unless otherwise noted in Models on page 3.

Installation

3A4019H 11


Outlet Pressure psi (MPa, bar)

1/4 Inch Fluid Plunger





0 (0, 0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0)250 (1.7, 17.2) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0)500 (3.4, 34.5) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.9 (0.1, 1.1) 23.0 (0.2, 1.6)750 (5.2, 51.7) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.3 (0.1, 1.1) 23.9 (0.2, 1.6) 34.4 (0.2, 2.4)

1000 (6.9, 68.9) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 20.4 (0.1, 1.4) 31.9 (0.2, 2.2) 45.9 (0.3, 3.2)1250 (8.6, 86.2) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 25.5 (0.2, 1.8) 39.9 (0.3, 2.7) 57.4 (0.4, 4.0)

1500 (10.3, 103.4) 15.0 (0.1, 1.0) 17.2 (0.1, 1.2) 30.6 (0.2, 2.1) 47.8 (0.3, 3.3) 68.9 (0.5, 4.7)1750 (12.1, 120.7) 15.0 (0.1, 1.0) 20.1 (0.1, 1.4) 35.7 (0.2, 2.5) 55.8 (0.4, 3.8) 80.4 (0.6, 5.5)2180 (15.0, 150.3) 15.0 (0.1, 1.0) 25.0 (0.2, 1.7) 44.5 (0.3, 3.1) 69.5 (0.5, 4.8) 100.1 (0.7, 6.9)2250 (15.5, 155.1) 15.0 (0.1, 1.0) 25.8 (0.2, 1.8) 45.9 (0.3, 3.2) 71.7 (0.5, 4.9)2500 (17.2, 172.4) 15.0 (0.1, 1.0) 28.7 (0.2, 2.0) 51.0 (0.4, 3.5) 79.7 (0.5, 5.5)2750 (19.0, 189.6) 15.0 (0.1, 1.0) 31.6 (0.2, 2.2) 56.1 (0.4, 3.9) 87.7 (0.6, 6.0)3136 (21.6, 216.2) 16.0 (0.1, 1.1) 36.0 (0.2, 2.5) 64.0 (0.4, 4.4) 100.0 (0.7, 6.9)3250 (22.4, 224.1) 16.6 (0.1, 1.1) 37.3 (0.3, 2.6) 66.3 (0.5, 4.6)3500 (24.1, 241.3) 17.9 (0.1, 1.2) 40.2 (0.3, 2.8) 71.4 (0.5, 4.9)3750 (25.9, 258.6) 19.1 (0.1, 1.3) 43.0 (0.3, 3.0) 76.5 (0.5, 5.3)4000 (27.6, 275.8) 20.4 (0.1, 1.4) 45.9 (0.3, 3.2) 81.6 (0.6, 5.6)4250 (29.3, 293.0) 21.7 (0.1, 1.5) 48.8 (0.3, 3.4) 86.7 (0.6, 6.0)4500 (31.0, 310.3) 23.0 (0.2, 1.6) 51.7 (0.4, 3.6) 91.8 (0.6, 6.3)4900 (33.8, 337.8) 25.0 (0.2, 1.7) 56.3 (0.4, 3.9) 100.0 (0.7, 6.9)5000 (34.5, 344.7) 25.5 (0.2, 1.8) 57.4 (0.4, 4.0)5250 (36.2, 362.0) 26.8 (0.2, 1.8) 60.3 (0.4, 4.2)5500 (37.9, 379.2) 28.1 (0.2, 1.9) 63.1 (0.4, 4.4)5750 (39.6, 396.4) 29.3 (0.2, 2.0) 66.0 (0.5, 4.6)6000 (41.4, 413.7) 30.6 (0.2, 2.1) 68.9 (0.5, 4.7)6250 (43.1, 430.9) 31.9 (0.2, 2.2) 71.7 (0.5, 4.9)6500 (44.8, 448.2) 33.2 (0.2, 2.3) 74.6 (0.5, 5.1)6750 (46.5, 465.4) 34.4 (0.2, 2.4) 77.5 (0.5, 5.3)7000 (48.3, 482.6) 35.7 (0.2, 2.5) 80.4 (0.6, 5.5)7250 (50.0, 499.9) 37.0 (0.3, 2.6) 83.2 (0.6, 5.7)7500 (51.7, 517.1) 38.3 (0.3, 2.6) 86.1 (0.6, 5.9)7750 (53.4, 534.3) 39.5 (0.3, 2.7) 89.0 (0.6, 6.1)8000 (55.2, 551.6) 40.8 (0.3, 2.8) 91.8 (0.6, 6.3)8250 (56.9, 568.8) 42.1 (0.3, 2.9) 94.7 (0.7, 6.5)8700 (60.0, 599.8) 44.4 (0.3, 3.1) 99.9 (0.7, 6.9)8750 (60.3, 603.3) 44.6 (0.3, 3.1)9000 (62.1, 620.5) 45.9 (0.3, 3.2)9250 (63.8, 637.8) 47.2 (0.3, 3.3)9500 (65.5, 655.0) 48.5 (0.3, 3.3)9750 (67.2, 672.2) 49.7 (0.3, 3.4)

10000 (68.9, 689.5) 51.0 (0.4, 3.5)10250 (70.7, 706.7) 52.3 (0.4, 3.6)10500 (72.4, 723.9) 53.6 (0.4, 3.7)10750 (74.1, 741.2) 54.8 (0.4, 3.8)11000 (75.8, 758.4) 56.1 (0.4, 3.9)11250 (77.6, 775.7) 57.4 (0.4, 4.0)11500 (79.3, 792.9) 58.7 (0.4, 4.0)11750 (81.0, 810.1) 59.9 (0.4, 4.1)12000 (82.7, 827.4) 61.2 (0.4, 4.2)



Installation

12 3A4019H


Outlet Pressure psi (MPa, bar)






0 (0, 0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0)250 (1.7, 17.2) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0)500 (3.4, 34.5) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0)750 (5.2, 51.7) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 20.8 (0.1, 1.4)

1000 (6.9, 68.9) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 19.3 (0.1, 1.3) 27.8 (0.2, 1.9)1250 (8.6, 86.2) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 15.4 (0.1, 1.1) 24.1 (0.2, 1.7) 34.7 (0.2, 2.4)

1500 (10.3, 103.4) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 18.5 (0.1, 1.3) 28.9 (0.2, 2.0) 41.7 (0.3, 2.9)1750 (12.1, 120.7) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 21.6 (0.1, 1.5) 33.8 (0.2, 2.3) 48.6 (0.3, 3.4)2000 (13.8, 137.9) 15.0 (0.1, 1.0) 15.0 (0.1, 1.0) 24.7 (0.2, 1.7) 38.6 (0.3, 2.7) 55.6 (0.4, 3.8)2250 (15.5, 155.1) 15.0 (0.1, 1.0) 15.6 (0.1, 1.1) 27.8 (0.2, 1.9) 43.4 (0.3, 3.0) 62.5 (0.4, 4.3)2500 (17.2, 172.4) 15.0 (0.1, 1.0) 17.4 (0.1, 1.2) 30.9 (0.2, 2.1) 48.2 (0.3, 3.3) 69.4 (0.5, 4.8)2750 (19.0, 189.6) 15.0 (0.1, 1.0) 19.1 (0.1, 1.3) 34.0 (0.2, 2.3) 53.0 (0.4, 3.7) 76.4 (0.5, 5.3)3000 (20.7, 206.8) 15.0 (0.1, 1.0) 20.8 (0.1, 1.4) 37.0 (0.3, 2.6) 57.9 (0.4, 4.0) 83.3 (0.6, 5.7)3250 (22.4, 224.1) 15.0 (0.1, 1.0) 22.6 (0.2, 1.6) 40.1 (0.3, 2.8) 62.7 (0.4, 4.3) 90.3 (0.6, 6.2)3600 (24.8, 248.2) 15.0 (0.1, 1.0) 25.0 (0.2, 1.7) 44.4 (0.3, 3.1) 69.4 (0.5, 4.8) 100.0 (0.7, 6.9)3750 (25.9, 258.6) 15.0 (0.1, 1.0) 26.0 (0.2, 1.8) 46.3 (0.3, 3.2) 72.3 (0.5, 5.0)4000 (27.6, 275.8) 15.0 (0.1, 1.0) 27.8 (0.2, 1.9) 49.4 (0.3, 3.4) 77.2 (0.5, 5.3)4250 (29.3, 293.0) 15.0 (0.1, 1.0) 29.5 (0.2, 2.0) 52.5 (0.4, 3.6) 82.0 (0.6, 5.7)4500 (31.0, 310.3) 15.0 (0.1, 1.0) 31.3 (0.2, 2.2) 55.6 (0.4, 3.8) 86.8 (0.6, 6.0)4750 (32.8, 327.5) 15.0 (0.1, 1.0) 33.0 (0.2, 2.3) 58.6 (0.4, 4.0) 91.6 (0.6, 6.3)5200 (35.9, 358.5) 16.0 (0.1, 1.1) 36.1 (0.2, 2.5) 64.2 (0.4, 4.4) 100.3 (0.7, 6.9)5250 (36.2, 362.0) 16.2 (0.1, 1.1) 36.5 (0.3, 2.5) 64.8 (0.4, 4.5)5500 (37.9, 379.2) 17.0 (0.1, 1.2) 38.2 (0.3, 2.6) 67.9 (0.5, 4.7)5750 (39.6, 396.4) 17.7 (0.1, 1.2) 39.9 (0.3, 2.8) 71.0 (0.5, 4.9)6000 (41.4, 413.7) 18.5 (0.1, 1.3) 41.7 (0.3, 2.9) 74.1 (0.5, 5.1)6250 (43.1, 430.9) 19.3 (0.1, 1.3) 43.4 (0.3, 3.0) 77.2 (0.5, 5.3)6500 (44.8, 448.2) 20.1 (0.1, 1.4) 45.1 (0.3, 3.1) 80.2 (0.6, 5.5)6750 (46.5, 465.4) 20.8 (0.1, 1.4) 46.9 (0.3, 3.2) 83.3 (0.6, 5.7)7000 (48.3, 482.6) 21.6 (0.1, 1.5) 48.6 (0.3, 3.4) 86.4 (0.6, 6.0)7250 (50.0, 499.9) 22.4 (0.2, 1.5) 50.3 (0.3, 3.5) 89.5 (0.6, 6.2)7500 (51.7, 517.1) 23.1 (0.2, 1.6) 52.1 (0.4, 3.6) 92.6 (0.6, 6.4)7950 (54.8, 548.1) 24.5 (0.2, 1.7) 55.2 (0.4, 3.8) 98.1 (0.7, 6.8)8100 (55.8, 558.5) 25.0 (0.2, 1.7) 56.3 (0.4, 3.9) 100.0 (0.7, 6.9)8250 (56.9, 568.8) 25.5 (0.2, 1.8) 57.3 (0.4, 4.0)8500 (58.6, 586.1) 26.2 (0.2, 1.8) 59.0 (0.4, 4.1)8750 (60.3, 603.3) 27.0 (0.2, 1.9) 60.8 (0.4, 4.2)9000 (62.1, 620.5) 27.8 (0.2, 1.9) 62.5 (0.4, 4.3)9250 (63.8, 637.8) 28.5 (0.2, 2.0) 64.2 (0.4, 4.4)9500 (65.5, 655.0) 29.3 (0.2, 2.0) 66.0 (0.5, 4.5)9750 (67.2, 672.2) 30.1 (0.2, 2.1) 67.7 (0.5, 4.7)10000 (68.9, 689.5) 30.9 (0.2, 2.1) 69.4 (0.5, 4.8)10250 (70.7, 706.7) 31.6 (0.2, 2.2)10500 (72.4, 723.9) 32.4 (0.2, 2.2)10750 (74.1, 741.2) 33.2 (0.2, 2.3)11000 (75.8, 758.4) 34.0 (0.2, 2.3)11250 (77.6, 775.7) 34.7 (0.2, 2.4)11500 (79.3, 792.9) 35.5 (0.2, 2.4)11750 (81.0, 810.1) 36.3 (0.3, 2.5)12000 (82.7, 827.4) 37.0 (0.3, 2.6)



Operation

3A4019H 13

Operation

Pressure Relief ProcedureFollow the Pressure Relief Procedure whenever you see this symbol.

NOTE: Always discharge fluid into an approved con-tainer or location.

1. Shut off all fluid and pneumatic lines (A, K, & P) using shutoff valves (H & D).

2. Use a flathead screwdriver to turn the prime/bleed valve (107) slowly counter-clockwise to relieve pres-sure. (Use a hex wrench to turn the prime/bleed valve housing (106) on PCI-xxx-xxH pumps. See Configuration Number Matrix, page 4.)

3. Slowly disconnect fluid lines (K & P) from check valves (L & M).

Flush the Equipment

• Flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts.

1. Follow the Pressure Relief Procedure.

2. Connect inlet to the supply source of the flushing fluid.

3. Connect outlet to a waste reservoir.

4. Run the pump until the dispensed fluid is predomi-nately flushing fluid.

5. Follow the Pressure Relief Procedure.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection and splashing fluid, follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing the equipment.

To avoid fire and explosion, always ground equipment and waste container. To avoid static sparking and injury from splashing, always flush at the lowest pos-sible pressure.

Operation

14 3A4019H

Prime the Pump

1. Verify all connections and fluid lines are tight.

2. In order to prime the pump, turn the prime valve (107) counter-clockwise.

NOTE: The pressure regulator and inlet pneumatic nee-dle valve both effect the pump cycle rate. After inlet pressure is set, the needle valve can serve as a speed control.

3. Adjust pneumatic regulator to desired pressure. See Minimum Pneumatic Pressures by Fluid Plunger Size and Outlet Pressures on page 10.

4. Open bleed-type pneumatic valve. Slowly turn pump needle valve counter-clockwise, increasing air/gas flow to the pump.

5. Keep the pump cycle rate less than 1 cycle every 3 seconds. The pump is primed when discharge from the prime valve (107) has transitioned from air, to bubbly liquid chemical, to pure liquid chemical.

6. Close the prime valve (107) tightly and verify that fluid has stopped draining from the port.

Calibrate Chemical Dosage

1. Begin the process by setting the pump to an esti-mated setting of the flow rate. See Baseline Chem-ical Dosage Settings, page 16, for tables of cycles per minute (CPM), and corresponding gallons per day (GPD) and liters per day (LPD).

2. Follow the instructions provided with your calibration gauge in conjunction with the Baseline Chemical Dosage Settings on page 16.

3. Adjust the cycle rate with the inlet pneumatic needle valve and/or the pressure regulator.

4. Repeat the test procedure to verify your changes. Repeat as necessary until the desired flow rate is achieved.

NOTICE

Pump runaway may occur if the needle valve is opened too far for pressure settings, causing damage to the packing seals (103).

Operation

3A4019H 15

Stroke Adjustment

This pump has three defined stroke adjustment posi-tions.

1. Expose the pneumatic motor rod (218) by removing the dust cover (10). See Disconnect Pump on page 21.

2. Push the split ring (9) up or down to expose the dowel pin (8).

3. Push out the pin using a screwdriver or punch.

4. Align the desired stroke hole (Long, Standard, or Short) with the hole in the fluid plunger (105). Use a screwdriver to push in the pin (8).

5. Push the split ring (9) into place to cover the pin (8).

6. Replace the dust cover (10).

FIG. 2 Retaining spring and connector pin

Long

Standard

Short

218

9

8

105

Operation

16 3A4019H

Baseline Chemical Dosage Settings

See Stroke Adjustment, page 15, for stroke adjust settings. See Performance Charts, starting on page 44, for maximum flows at any given pressure.

CPM

1/8 in. Fluid Plunger Pumps 3/16 in. Fluid Plunger Pumps

GPD (LPD) GPD (LPD)

Long Stroke Standard Stroke Short Stroke Long Stroke Standard Stroke Short Stroke

5 0.4 (1.5) 0.3 (1.1) 0.2 (0.8) 1.2 (4.4) 0.9 (3.3) 0.6 (2.2)

10 0.8 (3.0) 0.6 (2.3) 0.4 (1.5) 2.3 (8.7) 1.7 (6.5) 1.2 (4.4)

20 1.6 (6.1) 1.2 (4.5) 0.8 (3.0) 4.6 (17.5) 3.5 (13.1) 2.3 (8.7)

30 2.4 (9.1) 1.8 (6.8) 1.2 (4.5) 6.9 (26.2) 5.2 (19.6) 3.5 (13.1)

40 3.2 (12.1) 2.4 (9.1) 1.6 (6.1) 9.2 (34.9) 6.9 (26.2) 4.6 (17.5)

50 4.0 (15.1) 3.0 (11.4) 2.0 (7.6) 11.5 (43.7) 8.6 (32.7) 5.8 (21.8)

60 4.8 (18.2) 3.6 (13.6) 2.4 (9.1) 13.8 (53.4) 10.4 (39.3) 6.9 (26.2)

70 5.6 (21.2) 4.2 (15.9) 2.8 (10.6) 16.1 (61.1) 12.1 (45.8) 8.1 (30.6)

80 6.4 (24.2) 4.8 (18.2) 3.2 (12.1) 18.5 (69.8) 13.8 (52.4) 9.2 (34.9)

90 7.2 (27.2) 5.4 (20.4) 3.6 (13.6) 20.8 (78.6) 15.6 (58.9) 10.4 (39.3)

100 8.0 (30.3) 6.0 (22.7) 4.0 (15.1) 23.1 (87.3) 17.3 (65.5) 11.5 (43.7)

CPM


GPD (LPD) GPD (LPD)


5 - 1.5 (5.6) 1.0 (3.7) - 3.5 (13.1) 2.3 (8.7)

10 - 3.0 (11.2) 2.0 (7.5) - 6.9 (26.2) 4.6 (17.5)

20 7.9 (29.8) 5.9 (22.4) 3.9 (14.9) 18.5 (69.8) 13.8 (52.4) 9.2 (34.9)

30 11.8 (44.7) 8.9 (33.5) 5.9 (22.4) 27.7 (104.8) 20.8 (78.6) 13.8 (52.4)

40 15.7 (59.6) 11.8 (44.7) 7.9 (29.8) 36.9 (139.7) 27.7 (104.8) 18.5 (69.8)

50 19.7 (74.5) 14.8 (55.9) 9.8 (37.3) 46.1 (174.6) 34.6 (131.0) 23.1 (87.3)

60 23.6 (89.4) 17.7 (67.1) 11.8 (44.7) 55.4 (209.5) 41.5 (157.2) 27.7 (104.8)

70 27.6 (104.3) 20.7 (78.2) 13.8 (52.2) 64.6 (244.5) 48.4 (183.3) 32.3 (122.2)

80 31.5 (119.2) 23.6 (89.4) 15.7 (59.6) 73.8 (279.4) 55.4 (209.5) 36.9 (139.7)

90 35.4 (134.1) 26.6 (100.6) 17.7 (67.1) 83.0 (314.3) 62.3 (235.7) 41.5 (157.2)

100 39.4 (149.0) 29.5 (111.8) 19.7 (74.5) 92.3 (349.2) 69.2 (261.9) 46.1 (174.6)

CPM


GPD (LPD) GPD (LPD)


5 - 6.2 (23.3) 4.1 (15.5) - 9.6 (36.4) 6.4 (24.3)

10 - 12.3 (46.6) 8.2 (31.0) - 19.2 (72.8) 12.8 (48.5)

20 32.8 (124.2) 24.6 (93.1) 16.4 (62.1) 51.3 (194) 38.4 (145.5) 25.6 (97.0)

30 49.2 (186.3) 36.9 (139.7) 24.6 (93.1) 76.9 (291) 57.7 (218.3) 38.4 (145.5)

40 65.6 (248.3) 49.2 (186.3) 32.8 (124.2) 102.5 (388.0) 76.9 (291.0) 51.3 (194.0)

50 82.0 (310.4) 61.5 (232.8) 41.0 (155.2) 128.1 (485.1) 96.1 (363.8) 64.1 (242.5)

60 98.4 (372.5) 73.8 (279.4) 49.2 (186.3) 153.8 (582.1) 115.3 (436.5) 76.9 (291.0)

70 114.8 (434.6) 86.1 (326.0) 57.4 (217.3) 179.4 (679.1) 134.5 (509.3) 89.7 (339.5)

80 131.2 (496.7) 98.4 (372.5) 65.6 (248.3) 205.0 (776.1) 153.8 (582.1) 102.5 (388.0)

90 147.6 (558.8) 110.7 (419.1) 73.8 (279.4) 230.6 (873.1) 173.0 (654.8) 115.3 (436.5)

100 164.0 (620.9) 123.0 (465.6) 82.0 (310.4) 256.3 (970.1) 192.2 (727.6) 128.1 (485.1)

Operation

3A4019H 17

NOTE: Standard or short strokes are recommended for cycle rates less than 15 CPM.

CPM

3/4 in. Fluid Plunger Pumps

GPD (LPD)

Long Stroke Standard Stroke Short Stroke

5 - 13.8 (52.4) 9.2 (34.9)

10 - 27.7 (104.8) 18.5 (69.8)

20 73.8 (279.4) 55.4 (209.5) 36.9 (139.7)

30 110.7 (419.1) 83.0 (314.3) 55.4 (209.5)

40 147.6 (558.8) 110.7 (419.1) 73.8 (279.4)

50 184.5 (698.5) 138.4 (523.9) 92.3 (349.2)

60 221.4 (838.2) 166.1 (628.6) 110.7 (419.1)

70 258.3 (977.9) 193.7 (733.4) 129.2 (488.9)

80 295.2 (1117.6) 221.4 (838.2) 147.6 (558.8)

90 332.1 (1257.3) 249.1 (942.9) 166.1 (628.6)

100 369.0 (1396.9) 276.8 (1047.7) 184.5 (698.5)

Maintenance

18 3A4019H

Maintenance

Preventive Maintenance ScheduleThe operating conditions of your particular pump deter-mines how often maintenance is required. Establish a preventive maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for checking your pump.

Tighten Threaded ConnectionsCheck that all threaded connections are tight at routine intervals.

Tighten PackingsThe packings included in your pump have the ability to be adjusted to stop leaks that develop when the seals are worn. If a leak develops in the pump’s fluid section, tighten the packing nut clockwise by 1/16th of a turn, or lower, until the leak is eliminated. The life of the packing can be affected by over-tightening the packings. If the packing nut needs to be tightened repeatedly after short intervals, replace the packing.

StorageIf the pump is going to be stored for long periods, it is recommended that the pump be flushed with a light-weight oil or rust prohibiter to protect pump compo-nents. Store the pump with protective fluid inside when-ever possible.

Troubleshooting

3A4019H 19

Troubleshooting1. Follow Pressure Relief Procedure, page 13,

before checking or repairing pump.

2. Check all possible problems and causes before dis-assembling pump.

Problem Cause Solution

Pump runs, but the chemical does not discharge at the correct rate.

Inlet check is clogged with debris. Remove debris from check valve.

Inlet check o-ring is damaged.Evaluate the o-ring chemical compatibil-ity, and replace as required.

Air is in the pump head.

Ensure suction lines are tight, and then prime the pump.

When injecting into a gas line, inspect the outlet check valve to ensure gas is not back feeding into the pump head.

Packing leak.Tighten packing nut. If leak persists then evaluate packing chemical compatibility, and replace.

Inadequate chemical supply.Ensure the chemical tank is filled.

Inspect and replace chemical supply filter.

Incorrect calibration.Ensure the calibration gauge is function-ing properly with adequate venting.


Pump does not stroke.

Inadequate pneumatic supply.

If the pressure is too low then increase the pneumatic supply pressure.

If the volume is too low, then ensure the pneumatic supply volume is adequate to operate the pump.

Dirty supply gas.Install a filter

Replace the filter element

Inadequate internal lubrication.

Ensure pneumatic supply gas is clean and dry with a working filter. Then lubri-cate the air motor internals.

Add an oiler if pneumatic supply gas con-tains solvents that are washing out the factory grease. Graco oiler 237212.

Inconsistent pump changeover. Replace the pilot valves.

Stalling on one end of the stroke.Rebuild or replace the pneumatic valve.

Replace pilot valves.

Air is continuously exhausting from muf-fler.

Rebuild or replace pneumatic valve.

Air is continuously exhausting from motor piston rod.

Replace the piston rod u-cup.

Troubleshooting

20 3A4019H

Chemical is leaking from packing. Worn packing

Tighten the packing nut. If leaking per-sists then replace packing. NOTE: the packing nut is set from the factory, and does not require tightening upon initial installation.

Consult the Chemical Compatibility Guide to ensure the seal in use is compatible with the chemicals being pumped. NOTE: The Chemical Compatibility Guide can be found at www.graco.com.

Consult the Chemical Compatibility Guide to ensure the seal in use is designed to operate in the recommended temperature range. NOTE: The Chemical Compatibil-ity Guide can be found at www.graco.com.

Inspect the plunger for coating failure due to chemical or abrasive attack. Replace plunger as required.


Icing inside motor.Pneumatic motor is operating at a high pressure or high cycle rate.

Reduce pressure, cycle rate, or duty cycle of motor.

Reduce the dew-point of compressed air in the moisture coalescing filter.

Erratic of accelerated pump speed.

Exhausted fluid supply. Replace and reprime.

Worn or clogged check valves or packing.

Remove debris from check valve.

Replace check valve.


Repair

3A4019H 21

Repair

Pump

Disconnect Pump

1. Follow the Pressure Relief Procedure, page 13.

2. Remove the dust cover (10) by loosening the two screws. See FIG. 3.

3. Push the retaining spring up and push out the con-nector pin using a screwdriver or punch. See FIG. 4.

4. Loosen the fluid cylinder (101) and carefully slide away from the lower pump adapter (5).

Before servicing or repairing your pump, verify that pressure is relieved according to the Pressure Relief Procedure, page 13, and that all fluid and pneumatic lines are properly shut off, or sealed with compatible valves and disconnected.

FIG. 3 Remove dust cover

10FIG. 4 Retaining spring and connector pin

FIG. 5 Remove fluid cylinder

9 8

101

1

25

Repair

22 3A4019H

Pump Repair

1. Remove packing nut (104) from fluid cylinder (101).

2. Carefully remove bearings (102) and packing (103) from the fluid cylinder (101).

3. Replace packing (103) and bearings (102), if neces-sary. Lubricate prior to reassembly.

4. Reinsert the packing nut (104), packing (103), and bearings (102) into the fluid cylinder (101). Tighten packing nut (104) to distance as shown in FIG. 8.

NOTE: If the packing nut (104) is over-tightened, the pump may not complete a full stroke and seal life will be compromised.

FIG. 6 Remove parts from fluid cylinder

105

104

102

103

102

101

Seal lipsfacing down

FIG. 7 Packing detailed view

FIG. 8 Tightening the packing nut

Tan

Gray

Black

Tan

Gray

Gray

Repair

3A4019H 23

Fluid Plunger Repair

1. Disconnect Pump, page 21.

2. Remove the fluid plunger (105).

3. Inspect the fluid plunger (105) for wear or damage, and replace if necessary.

Reconnect Pump

1. Align the hole in the displacement rod with the hole in the pneumatic motor rod. Use a screwdriver to push in the pin (8).

2. Screw the fluid cylinder into the adapter plate (nn) until it stops. Tighten fluid cylinder (101) to 30 ft-lbs (40 N•m).

3. Align the hole in the displacement rod with the hole in the pneumatic motor rod. Use a screwdriver to push in the pin (8).

4. Push the retaining spring (9) into place to cover the pin.

5. Replace the dust cover (10) and secure by tighten-ing the two screws.

NOTICEThe pump can be damaged if the fluid cylinder is not screwed all the way into the adapter plate. Be sure to fully screw the fluid cylinder (101) into the adapter plate (5).

FIG. 9 Reconnect fluid cylinder

101

104

105

5

1

2


FIG. 11 Replace dust cover

9 8

10

Repair

24 3A4019H

Check Valves

Inlet Check Valve Repair


2. Remove the inlet check valve assembly (108).

3. Remove the retaining nut (108a) and piston (108b).

4. Remove the piston o-ring (108c).

5. Inspect parts for wear, replace as needed.

6. Install the piston o-ring (108c), piston (108b), and retaining nut (108a).

7. Reconnect the inlet check valve assembly (108).

Inlet Check Valve Repair (models PCI-xxx-xxH only)


2. Remove the inlet check valve assembly (108).

3. Separate the front housing (108d) from the back housing (108e).

4. Remove the piston (108b) and the piston o-ring (108c).


6. Install the piston o-ring (108c) and piston (108b) in the back housing (108e).

7. Reattach the front housing (108d) to the back hous-ing (108e).

8. Reconnect the inlet check valve assembly (108).

FIG. 12 Inlet check valve assembly

108a

108b

108c

108

FIG. 13 Inlet check valve assembly

108d

108b

108c

108e108

Repair

3A4019H 25

Outlet Check Valve Repair


2. Remove the outlet check valve assembly (109).

3. Remove the retaining nut (109a), spring (109b), and piston (109c).

4. Remove the piston o-ring (109d).


6. Install the piston o-ring (109d), piston (109c), spring (109b), and retaining nut (109a).

7. Reconnect the outlet check valve assembly (109).

Outlet Check Valve Repair (models PCI-xxx-xxH only)


2. Remove the outlet check valve assembly (109).

3. Separate the front housing (109e) from the back housing (109f).

4. Remove the spring (109b), piston (109c), and piston o-ring (109d).


6. Install the piston o-ring (109d), piston (109c), and spring (109b).

7. Reattach the back housing (109f) to the front housing (109e)

8. Reconnect the outlet check valve assembly (109).

FIG. 14 Outlet check valve assembly

109

109d109c

109b109a

FIG. 15 Outlet check valve assembly

109e

109d109c

109b109f

109

Repair

26 3A4019H

Pneumatic Valve

Replace Complete Pneumatic Valve

1. Stop the pump. Follow Pressure Relief Procedure, page 13.

2. Disconnect the pneumatic line to the motor.

3. See FIG. 22 on page 31. Remove four screws (211). Remove the pneumatic valve (214) and gasket (209*).

4. To repair the pneumatic valve, go to Disassemble the Pneumatic Valve, page 26. To install a replace-ment pneumatic valve, continue with step 5.

5. Align the new pneumatic valve gasket (209*) on the manifold, then attach the pneumatic valve (214). Torque screws (211) to 95-105 in-lb (11-12 N•m).

6. Reconnect the pneumatic line to the motor.

Replace Seals or Rebuild Pneumatic Valve

NOTE: Pneumatic Valve Seal Kits are available. See page 40. Parts are marked with an †.

Pneumatic Valve Repair Kits are available. See page 40. Parts are marked with an .

Pneumatic Valve End Cap Kits are available. See page 40. Parts are marked with an .

Disassemble the Pneumatic Valve

1. Perform steps 1-3 under Replace Complete Pneu-matic Valve, page 26.

2. See FIG. 16. Use a 2 mm or 5/64 in. hex key to remove two screws (309†). Remove the valve plate (305), cup (312), and spring (311).

3. See FIG. 17. Remove the snap ring (310) from each end. Use the piston to push the end caps (307) out of the ends. Remove end cap o-rings (306†).

4. Remove the piston (302). Remove the u-cup seals (308†) from each end, and the detent assembly (303) and detent cam (304) from the center.

FIG. 16. Pneumatic Plate Removal

309†

305

312311

ti16284a

Repair

3A4019H 27

FIG. 17. Pneumatic Valve Assembly

1 Apply lubricant.

310

307

307

†309

305

312

311303

302

†308

†308

301

304

310ti16213a

†306

†306

1

1

1

1

1

1

1

1

Repair

28 3A4019H

Reassemble the Pneumatic Valve

1. See FIG. 17. Lubricate detent cam (304) and install into housing.

2. See FIG. 18. Lubricate the u-cups (308†) and install on the piston (302) with lips facing toward the center of the piston.

3. See FIG. 17. Lubricate both ends of the piston (302) and install it in the housing.

4. Lubricate and install the detent assembly (303) into the piston.

5. Lubricate new o-rings (306†) and install on the end caps (307). Install the end caps into the hous-ing.

6. Install a snap ring (310) on each end to hold end caps in place.

7. Install the spring (311). Lubricate and install the pneumatic valve cup (312), see FIG. 19. Align the small round magnet with the pneumatic inlet.

8. Install the valve plate (305). Tighten the screws (309†) to hold it in place.

Replace Pilot Valves

1. Stop the pump. Follow Pressure Relief Procedure, page 13.

2. Disconnect the pneumatic line to the motor.

3. See FIG. 20. Push the safety spring (9) down and hold to access the pilot valve (213) on the bottom cover (201).

4. See FIG. 22 on page 31. Use a 10 mm wrench to remove the old pilot valves (213) from the top and bottom covers.

5. Lubricate and install the new pilot valves (213). Torque to 95-105 in-lb (11-12 N•m).

FIG. 18. Pneumatic Valve U-cup Installation

Lips face down

Lips face up

†308

†308

302

ti12754a

FIG. 19. Pneumatic Valve Cup Installation

312

ti16283aMagnet

Repair

3A4019H 29

Disconnect the Pneumatic Motor

1. Stop the pump.

2. Flush the pump, if possible (see page 13). Follow Pressure Relief Procedure, page 13.

3. Disconnect the pneumatic line and fluid line and remove the dust guard (10). (See FIG. 3)

4. See FIG. 20. Push the split spring (9) up or down and hold to access the dowel pin (8). Push out the pin, using a screwdriver or punch.

5. Remove the nuts (6) from the bottom of the tie rods (3).

6. Remove the pump lower (7). The adapter plate (5) will remain attached to the pump lower.

7. Remove the split spring (9).

8. Loosen the nuts (4) at the top of the tie rods, then remove the tie rods. The mounting bracket (1) is loosened from the motor as the tie rods are removed.

9. Take the motor to a work bench. See Repair Pneumatic Motor on page 30.

Reconnect the Pneumatic Motor1. Replace the motor on the mounting bracket (2).

2. Screw the tie rods (3) into the motor, with the top hex nuts (4) attached. Torque the tie rods to 5-10 ft-lb (7-13 N•m).

NOTE: Always tighten the tie rods (3) before tightening the top hex nuts (4).

3. Tighten the top hex nuts (4) to secure the mounting bracket (2).

4. Slide the pump with the adapter plate (5) attached onto the tie rods (3). Ensure that the split spring (9) is in place and the pump outlet is oriented as desired.

5. Install the tie rod nuts (6). Torque to 100 in-lb (11 N•m).

6. Align the hole in the fluid plunger (105) with the hole in the pneumatic motor piston rod (218). Use a screwdriver to push in the dowel pin (8).

7. Push the split spring (9) into place to cover the dowel pin (8).

8. Replace the dust guard(10).


98

5

6

3

105

218

7

4

1

Repair

30 3A4019H

Repair Pneumatic Motor

NOTE: Complete Pneumatic Motor Replacement Kits are available. Order 24G694 (3.5 in. motor).

NOTE: Pneumatic Motor Seal Kits are available. See page 38 for the correct kit for your motor. Parts included in the kit are marked with an asterisk (*). For best results, use all the parts in the kit.

Disassemble the Pneumatic Motor

1. See FIG. 22. Use a 10 mm socket wrench to remove four screws (211). Remove the pneumatic valve (214) and gasket (209*†).

2. Remove four screws (211) and remove the manifold (220) and two gaskets (208*).

3. Use a 10 mm socket wrench to remove the pilot valves (213) from the top and bottom cover.

4. Use a 13 mm socket wrench to remove the tie bolts (212).

5. Remove the top cover (210). Remove the o-ring (202*). On 3.5 in. motors only, remove the plug (231) and o-ring (230*).

6. Remove the shield (206) and cylinder (205).

7. Remove the o-ring (204*) from the piston.

8. Secure the piston (219) in a vise with soft jaws. Use a wrench on the flats of the rod (218) to remove the rod and bottom cover assembly (201) from the pis-ton.

9. Remove the rod from the bottom cover assembly.

10. Remove retaining ring (217), u-cup seals (207*), and o-ring (202*) from the bottom cover.

Reassemble the Pneumatic Motor

NOTE: For easier reassembly, start with the top cover (210) turned over on the workbench and assemble the pneumatic motor upside-down.

1. Lubricate and install the o-ring (202*) on the top cover (210).

2. Lubricate the inside of the cylinder (205). Lower the cylinder onto the top cover (210).

3. Install the shield (206) around the cylinder (205) and in the groove on the top cover (210).

4. See FIG. 21. Lubricate and install new u-cup seal (207*) in the bottom of the bearing in the bottom cover (201). The lips must face down. Lubricate and install new u-cup seal (207*) in the top of the bear-ing. Lips must face up Install retaining ring (217).

FIG. 21. Pneumatic Motor U-cup Installation

*207

*207

ti16285a

Lips face up

Lips face down.

Repair

3A4019H 31

FIG. 22. Pneumatic Motor Assembly

201

215

214213

211

202*

203

204*

219

209*†

208*

*207

205

206

210

212

220

*202

208*

211

213

*217

218

*207

*230

231

1

1

1

1

1

1

1

1

Apply lubricant.1

1

Repair

32 3A4019H

5. Lubricate and install the o-ring (202*) on the bottom cover (201).

6. Carefully push the threaded end of the rod (218) up through the bottom cover (201).

7. Apply 16G561 adhesive to the threads of the rod (218). Screw the piston (219) onto the rod. Place the piston in a vise with soft jaws and torque to 35-40 ft-lb (47-54 N•m).

8. Lubricate and install the o-ring (204*) on the piston (219).

9. See FIG. 23. Carefully place the bottom cover/piston assembly on the cylinder (205), sliding the piston (219) into the cylinder. The manifold surfaces of the top and bottom covers must align. Be sure the shield (206) is in the groove on both the top and bot-tom covers.

10. Install the tie bolts (212) hand tight.

11. Install two gaskets (208*) on the manifold (220). Install the manifold (220). Torque screws (211) to 95-105 in-lb (10.7-11.9 N•m).

NOTE: The manifold is reversible for ease of placement of muffler or remote exhaust.

12. Align the pneumatic valve gasket (209*†) on the manifold, then attach the pneumatic valve (214). Torque screws (211) to 95-105 in-lb (11-12 N•m).

13. Tighten the tie bolts (212) halfway. Work in a criss-cross pattern. Check that the shield (206) remains in the grooves on both covers. Continue tightening the bolts in pattern to 11-13 ft-lb (15-18 N•m).

14. Lubricate the o-ring (230*). Install it and the plug (231) in the top cover (210).

15. Lubricate and install pilot valves (213) in top and bottom cover. Torque to 95-105 in-lb (11-12 N•m).

16. See Reconnect the Pneumatic Motor on page 29.

FIG. 23. Align Shield in Grooves on Covers

groove

groove

201

206

ti16281a

210

Parts

3A4019H 33

Parts

Python XL Pneumatic PumpPCI-350-25H-XA-A shown

105

10

102

102

103

104

117

107

106

109

101

108

117

8

9

6

5

3

4

2

1 117

21

26

22

21

24

25

14

15

13

112

Parts

34 3A4019H

Python XL Pump Lower Parts List

Replacement Danger and Warning labels, tags, and cards are available at no cost.

* Not included with PCI-xxx-xxH configurations.

† Included with Lower Kit. See Lower Configuration on page 4.

Ref. Part Description Qty.

1 B32982 Pneumatic motor, 2.5 in. 1

B32981 Pneumatic motor, 3.5 in. 1

B32980 Pneumatic motor, 4.5 in. 1

2 B32272 Wall bracket, 2.5 in., 3.5 in. 1

B32278 Wall Bracket, 4.5 in. 1

3 B32273 Motor tie rod 3

4 -- Jam hex nut 3

5 B32269 Lower adapter (1/8 in., 3/16 in., 1/4 in., 3/8 in., and 1/2 in. plungers)

1

B32270 Lower adapter (5/8 in. and 3/4 in. plungers)

1

6 -- Nyloc nut, stainless steel 3

7 -- Pump lower (includes ref. 101-117) 1

8† B32268 Dowel pin, stainless steel 1

9† B32268 Split ring, stainless steel 1

10 B32767 Dust/hand guard, 2.5 in. 1

B32271 Dust/hand guard, 3.5 in. 1

B32277 Dust/hand guard, 4.5 in. 1

11 -- ES screw 2

12 -- Nipple fitting, hex 1

13 B32818 Needle valve, Viton, stainless steel, NPT, 40 PSI

1

B32819 Needle valve, Viton, stainless steel, NPT, 50 PSI

1


1


1


1


1

14 -- Tee, 1/4m x 1/4m x 1/4f 1

15 B32822 Safety valve, 40 PSI 1

B32823 Safety valve, 50 PSI 1

127731 Safety valve, 70 PSI 1



113498 Safety valve, 100 PSI 1

21 B32274 Coved spacer 4

22 B32274 Stand leg 2

23 B32274 Hex head bolt, stainless steel 4

24 B32274 Spring lock washer 4

25 B32274 Hex nut 4

26 B32274 Stand leg plug 4

101 See Table 3, pg 35

Fluid cylinder 1

102† See Table 4, pg 35

Plunger bearings, included with packing (ref. 103)

2


Packing 1


Packing nut 1


Fluid Plunger 1

106† B32191 Priming bleed valve housing, stan-dard pressure (3/8 in., 1/2 in., 5/8 in., and 3/4 in. plungers)

1

B32250 Priming bleed valve housing, high pressure (1/8 in., 3/16 in., 1/4 in. plungers)

1

107*† B32192 Priming bleed valve; included with priming bleed valve housing (ref. 106)

1


Inlet valve check 1


Outlet valve check 1

112 17G320 Warning label, adhesive 1

117† -- Cap plug 2

Ref. Part Description Qty.

Parts

3A4019H 35

Table 2: Fluid Plungers (ref. 105)

Table 3: Fluid Cylinders (ref. 101)

Table 4: Packing Stacks (ref. 103), including Plunger Bearings (ref. 102)

Table 5: Packing Nuts (ref. 104)

Ref

Part Numbers by Fluid Plunger Size Diameter

Qty.1/8 in. 3/16 in. 1/4 in. 3/8 in. 1/2 in. 5/8 in. 3/4 in.

Chromex-Coated Fluid Plungers

105 B32826 B32827 B32254 B32255 B32256 B32257 B32258 1

Ceramic-Coated Fluid Plungers

105 B32828 B32829 B32259 B32260 B32261 B32262 B32263 1

Ref



101 B32180 B32181 B32275 B32183 B32184 B32185 B32180 1

Ref



FKM

103 B32115 B32119 B32094 B32098 B32102 B32123 B32127 1

FKMETP

103 B32116 B32120 B32095 B32099 B32103 B32124 B32128 1

HNBR

103 B32117 B32121 B32096 B32100 B32104 B32125 B32129 1

FFKM

103 B32118 B32122 B32097 B32101 B32105 B32126 B32130 1

TFE/P

103 B32033 B32041 B32042 B32043 B32044 B32085 B32086 1

Ref



104 B32187 B32187 B32264 B32265 B32266 B32267 B32267 1

Parts

36 3A4019H

Table 6: Inlet Valve Check (ref. 108)

Table 7: Outlet Valve Check (ref. 109)

Ref



FKM

108 B32226 B32226 B32226 B32024 B32024 B32024 B32024 1

FKMETP

108 B32228 B32228 B32228 B32026 B32026 B32026 B32026 1

HNBR

108 B32230 B32230 B32230 B32113 B32113 B32113 B32113 1

FFKM

108 B32232 B32232 B32232 B32028 B32028 B32028 B32028 1

TFE/P

109 B32806 B32806 B32806 B32610 B32610 B32610 B32610 1

Ref



FKM

109 B32227 B32227 B32227 B32025 B32025 B32025 B32025 1

FKMETP

109 B32229 B32229 B32229 B32027 B32027 B32027 B32027 1

HNBR

109 B32231 B32231 B32231 B32114 B32114 B32114 B32114 1

FFKM

109 B32233 B32233 B32233 B32029 B32029 B32029 B32029 1

TFE/P

109 B32807 B32807 B32807 B32608 B32608 B32608 B32608 1

Parts

3A4019H 37

Pneumatic Motor Parts

Part No. B32770, 2.5 in. (63.5 mm); B32251, 3.5 in. (88.9 mm), shown

‡ These items are only available in Air Motor Kits B32251 and B32770

201‡

215‡214

213 211‡

202*

203‡

204*

219‡

209*†208*

*207

205‡

206‡

210‡

212‡

220‡

*202

208*

211

213

*217

218‡

*207

*230‡

231‡

Parts

38 3A4019H

Pneumatic Motor PartsPart numbers shown: B32770: 2.5 in. (63.5 mm)B32251: 3.5 in. (88.9 mm)B32276: 4.5 in. (114.3 mm)

Replacement Danger and Warning labels, tags, and cards are available at no cost.

† Included in Pneumatic Valve Seal Kit 24A535. See page 40.

Included in Pneumatic Valve Repair Kit 24A537. See page 40.

* Included in Pneumatic Motor Seal Kit 24A539 (2.5 in.), 24G700 (3.5 in.).

Ref. Part Description Qty

201 -- Cover, bottom 1202* -- O-Ring, cover 2203 -- Bearing 1204* -- O-Ring, piston 1205 -- Cylinder, motor 1206 B32830 2.5 in. cover, cylinder (includes English warning label) 1

B32831 3.5 in. cover, cylinder (includes English warning label) 1B32832 4.5 in. cover, cylinder (includes English warning label) 1

229 15W719 Label, warning (French and Spanish) (not shown) 1207* -- Seal, u-cup 2208* -- Gasket, manifold 2209*† -- Gasket, pneumatic valve 1210 -- Cover, top 1211 -- Screw, M6 x 25 8212 -- Bolt, tie, hex head 2, 3213 24A366 Valve, pilot (pack of 2) 1214 24A351 Valve, pneumatic; includes items 209 and 211 (qty 4) 1215 -- Muffler 1217* -- Ring, retaining 1218 -- Rod, pneumatic motor 1219 -- Kit, piston, motor; includes 204 and 218, and 16G561 adhesive. 1220 -- Manifold, assembly, includes 208, 209, and 211 (qty. 4) 1230* -- O-Ring, top plug 1231 -- Plug, top cover (ref. 210) 1

24A539* 2.5 in. Motor Seal Kit 124G700* 3.5 in. Motor Seal Kit 124E986 4.5 in. Motor Seal Kit 1

Parts

3A4019H 39

Pneumatic Valve Parts

310

307

307

†309

305

312

311303

302

†308

†308

301

304

310ti16213a

†306

†306

Parts

40 3A4019H

Pneumatic Valve Parts

Complete Pneumatic Valve Replacement Kit 24A351

To replace the complete pneumatic valve, order Pneumatic Valve Replacement Kit 24A351 (2.5 in., 3.5 in.) or Kit 24A352 (4.5 in.). The kit includes items 301-312 below, and items 209 and 211 on page 38.

Pneumatic Valve Repair Kits

Pneumatic valve parts are not sold individually. The table below shows possible kit options for each part.

† Included in Pneumatic Valve Seal Kit 24A535.

Included in Pneumatic Valve Repair Kit 24A537.

Included in Pneumatic Valve End Cap Kit 24A360.

Replacement screws (309) are available in a pack of 10. Order Kit 24A359.

Ref. Description Qty.

Pneumatic ValveRepair Kit 24A537 (2.5 in., 3.5 in.)24A538 (4.5 in.)

Pneumatic Valve Seal Kit 24A535 (2.5 in., 3.5 in.)24A536 (4.5in.)

Pneumatic Valve End Cap Kit24A360 (2.5 in., 3.5 in.)24A361 (4.5 in.)

301 HOUSING 1302 PNEUMATIC VALVE PISTON 1

303 DETENT PISTON ASSEMBLY 1

304 DETENT CAM 1

305 PLATE, pneumatic valve 1

306† O-RING 2

307 CAP 2

308† U-CUP 2

309† SCREW 2

310 SNAP RING 2

311 DETENT SPRING 1

312 CUP 1

Kits and Accessories

3A4019H 41

Kits and AccessoriesAdditional Kits & Accessories

Part No. Description

B32045 225-750 PSI Pressure Relief Valve Kit (Adjustable)







B32088 SST Calibration Column Kit

B32089 SST Manifold Assembly Kit

B32157 316 SST Ball Valve Kit, 3/4” NPT(F)

B32158 Fluid Filter 6000 PSI

B32159 Fluid Filter 10000 PSI

B32160 Float Switch

B32162 1/4 in. NPT(F) X 1/4 in. NPT(F) Check Kit

B32038 FKM Large (3/8 in. - 3/4 in.) Inlet and Outlet Check Valve Repair Kit (includes a spring and piston o-rings)

B32039 FKM ETP Large (3/8 in. - 3/4 in.) Inlet and Outlet Check Valve Repair Kit (includes a spring and piston o-rings)

B32040 FFKM Large (3/8 in. - 3/4 in.) Inlet and Out-let Check Valve Repair Kit (includes a spring and piston o-rings)

B32111 HNBR Large (3/8 in. - 3/4 in.) Inlet and Out-let Check Valve Repair Kit (includes a spring and piston o-rings)

B32870 TFE/P Large (3/8 in. - 3/4 in.) Inlet and Out-let Check Valve Repair Kit (includes a spring and piston o-rings)

B32224 FKM Small (1/4 in.) Inlet and Outlet Check Valve Repair Kit (includes a spring and pis-ton o-rings)

B32225 FKM ETP Small (1/4 in.) Inlet and Outlet Check Valve Repair Kit (includes a spring and piston o-rings)

B32235 FFKM Small (1/4 in.) Inlet and Outlet Check Valve Repair Kit (includes a spring and pis-ton o-rings)

B32234 HNBR Small (1/4 in.) Inlet and Outlet Check Valve Repair Kit (includes a spring and pis-ton o-rings)

B32871 TFE/P Small (1/4 in.) Inlet and Outlet Check Valve Repair Kit (includes a spring and pis-ton o-rings)

B32240 HF4 to 1/4 in. Adapter; 10,000 PSI (1/8 in. - 3/16 in. plungers)

B32686 Stroke Adjuster Kit

237212 Pneumatic Lubricator

AFLAS Air Motor Upgrade Kits

Part No. Description

B33067* 2.5” AFLAS air motor upgrade



* includes ref. 204, 207, 308, and 311.

Dimensions

42 3A4019H

Dimensions

Python XL Pump Dimensions

FIG. 24 Python Pump Dimensions

Size A B C D E F G

250 24.0 in.(61.0 cm)

14.5 in.(36.8 cm)

16.75 in.(42.5 cm)

17.75 in.(45.1 cm)

8.0 in.(20.3 cm)

7.62 in.(19.4 cm)

6.0 in.(15.2 cm)

350 24.0 in.(61.0 cm)

14.5 in.(36.8 cm)

16.75 in.(42.5 cm)

17.75 in(45.1 cm)

8.0 in.(20.3 cm)

3.62 in.(9.2 cm)

7.70 in.(19.6 cm)

450 24.0 in.(61.0 cm)

14.5 in.(36.8 cm)

16.75 in.(42.5 cm)

19.25 in.(48.9 cm)

9.94 in.(25.5 cm)

13.16 in.(33.4 cm)

9.19 in.(23.3 cm)

Dimensions

3A4019H 43

Wall Bracket Mounting Hole Diagram, 2.5 in. & 3.5 in.

Wall Bracket Mounting Hole Diagram, 4.5 in.

2 x 0.281 (9/32) in. (7 mm).For wall mount only.

TI16289a

4.40 in. (112 mm)

2 x 0.312 (5/16) in. (8 mm).For wall mount or to attach

stand to bracket.

5.10 in. (130 mm)

2.69 in. (68 mm)

2 x 0.48 in. (12 mm)

2 x 0.62 in. (16 mm)

2 x 0.35 in. (9 mm)

6.6 in. (168 mm)

4.40 in. (112 mm)2 x 0.281 (9/32) in. (7 mm).

For wall mount only.

2 x 0.312 (5/16) in. (8 mm).For wall mount or to attach

stand to bracket.

2 x 1.1 in. (28 mm)

TI31938

2.69 in. (68 mm)

2 x 0.62 in. (16 mm)

Dimensions

44 3A4019H

Performance Charts2.5 in. Motors1/8 in. Plunger (PCI-250-13)

3/16 in. Plunger (PCI-250-19)

FIG. 25

00

1(3.8)

2(7.6)

3(11.4)

4(15.1)

5(18.9)

6(22.7)

7(26.5)

8(30.3)

9(34.1)

2000(13.79)(137.9)

4000(27.58)(275.8)

6000(41.37)(413.7)

8000(55.16)(551.6)

10000(68.95)(689.5)

12000(82.74)(827.4)

A

B

Outlet Pressure - PSI (MPa, Bar)

FIG. 26

00

5(19)

10(38)

15(57)

20(76)

25(95)

2000(13.79)(137.9)

4000(27.58)(275.8)

6000(41.37)(413.7)

8000(55.16)(551.6)

10000(68.95)(689.5)

12000(82.74)(827.4)

A B C D


Inlet Pressure - PSI(MPa, Bar)A-15 (0.10, 1.0)B-25 (0.17, 1.7)C-50 (0.34, 3.4)D-75 (0.43, 4.3)

Inlet Pressure - PSI(MPa, Bar)A-15 (0.10, 1.0)B-25 (0.17, 1.7)

Dimensions

3A4019H 45



FIG. 27

0

5(19)

10(38)

15(57)

20(76)

25(95)

30(114)

35(133)

40(151)

0 2000(13.79)(137.9)

4000(27.58)(275.8)

6000(41.37)(413.7)

8000(55.16)(551.6)

10000(68.95)(689.5)

1000(6.89)(68.9)

3000(20.68)(206.8)

5000(34.47)(344.7)

7000(48.26)(482.6)

9000(62.05)(620.5)

A B C D E


GPD(LPD)

Inlet Pressure -PSI(MPa, Bar)A-15 (0.10, 1.0)B-25 (0.17, 1.7)C-50 (0.34, 3.4)D-75 (0.43, 4.3)E-100 (0.69, 6.9)

FIG. 28

0

0

20(76)

40(151)

60(227)

80(303)

100(379)

2000(13.79)(137.9)

3000(20.68)(206.8)

1000(6.89)(68.9)

4000(27.58)(275.8)

4500(31.03)(310.3)

1500(10.34)(103.4)

2500(17.24)(172.4)

500(3.45)(34.5)

3500(24.13)(241.3)

A B C D E


GPD(LPD)

Inlet Pressure - PSI(MPa, Bar)A-15 (0.10, 1.0)B-25 (0.17, 1.7)C-50 (0.34, 3.4)D-75 (0.52, 5.2)E-100 (0.69, 6.9)

Dimensions

46 3A4019H



FIG. 29

0

20(76)

40(151)

60(227)

80(303)

100(379)

120(454)

140(530)

160(606)

180(681)

0 2000(13.79)(137.9)

1000(6.89)(68.9)

1500(10.34)(103.4)

2500(17.24)(172.4)

500(3.45)(34.5)

A B C D E


GPD(LPD)

Inlet Pressure -PSI(MPa, Bar)A-15 (0.10,1.0)B-25 (0.17,1.7)

FIG. 30

0

50(189)

100(379)

150(568)

200(757)

250(946)

300(1136)

0 1000(6.89)(68.9)

800(5.52)(55.2)

600(4.14)(41.4)

400(2.76)(27.6)

200(1.38)(13.8)

1200(8.27)(82.7)

1400(9.65)(96.5)

1600(11.03)(110.3)

A B C D E



Dimensions

3A4019H 47


3.5 in. Motors


FIG. 31

0

50(189)

100(379)

150(568)

200(757)

250(946)

300(1136)

350(1325)

400(1514)

0 1000(6.89)(68.9)

800(5.52)(55.2)

600(4.14)(41.4)

400(2.76)(27.6)

200(1.38)(13.8)

1200(8.27)(82.7)

A B C D E


FIG. 32

0

5(19)

10(38)

15(57)

20(76)

25(95)

30(114)

35(133)

40(151)

45(170)

0 2000(13.79)(137.9)

4000(27.58)(275.8)

6000(41.37)(413.7)

8000(55.16)(551.6)

14000(96.53)(965.3)

12000(82.74)(827.4)

10000(68.95)(689.5)

A B C D


GPD(LPD)

Inlet Pressure -PSI(MPa, Bar)A-15 (0.10, 1.0)B-25 (0.17, 1.7)C-50 (0.34, 3.4)


Dimensions

48 3A4019H



FIG. 33

0

0

20(76)

40(151)

60(227)

80(303)

100(379)

8000(55.16)(551.6)

9000(62.05)(620.5)

2000(13.79)(137.9)

3000(20.68)(206.8)

1000(6.89)(68.9)

4000(27.58)(275.8)

5000(34.47)(344.7)

6000(41.37)(413.7)

7000(48.26)(482.6)

A B C D E


GPD(LPD)

Inlet Pressure -PSI(MPa, Bar)A-15 (0.10, 1.0)B-25 (0.17, 1.7)C-50 (0.34, 3.4)D-75 (0.52, 5.2)

FIG. 34

0

20(76)

40(151)

60(227)

80(303)

100(379)

120(454)

140(530)

160(606)

180(681)

0 2000(13.79)(137.9)

4000(27.58)(275.8)

3000(20.68)(206.8)

1000(6.89)(68.9)

5000(34.47)(344.7)

A B C D E


GPD(LPD)


Dimensions

3A4019H 49



FIG. 35

0

50(189)

100(379)

150(568)

200(757)

250(946)

300(1136)

0 500(3.45)(34.5)

2000(13.79)(137.9)

3000(20.68)(206.8)

1000(6.89)(68.9)

1500(10.34)(103.4)

2500(17.24)(172.4)

A B C D E


GPD(LPD)


FIG. 36

0

50(189)

100(379)

150(568)

200(757)

250(946)

300(1136)

350(1325)

400(1514)

0 500(3.45)(34.5)

2000(13.79)(137.9)

1000(6.89)(68.9)

1500(10.34)(103.4)

A B C D E


GPD(LPD) Inlet Pressure -

PSI(MPa, Bar)A-15 (0.10, 1.0)B-25 (0.17, 1.7)C-50 (0.34, 3.4)D-75 (0.52, 5.2)

Dimensions

50 3A4019H

4.5 in. Motors



FIG. 37

00

5(19)

10(38)

15(57)

20(76)

25(95)

30(114)

35(133)

40(151)

2000(13.79)(137.9)

4000(27.58)(275.8)

6000(41.37)(413.7)

8000(55.16)(551.6)

10000(68.95)(689.5)

12000(82.74)(827.4)

A

B

C


FIG. 38

00

10(38)

20(76)

30(114)

40(151)

50(189)

60(227)

70(265)

80(303)

90(341)

100(379)

2000(13.79)(137.9)

4000(27.58)(275.8)

6000(41.37)(413.7)

8000(55.16)(551.6)

10000(68.95)(689.5)

12000(82.74)(827.4)

A B C D


Inlet Pressure - PSI(MPa, Bar)A-15 (0.10, 1.0)B-25 (0.17, 1.7)C-50 (0.34, 3.4)D-75 (0.52, 5.2)

Inlet Pressure - PSI(MPa, Bar)A-15 (0.10, 1.0)B-25 (0.17, 1.7)C-50 (0.34, 3.4)

Dimensions

3A4019H 51



FIG. 39

0

20(76)

40(151)

60(227)

80(303)

100(379)

120(454)

140(530)

160(606)

180(681)

0

A B C D E

8000(55.16)(551.6)

2000(13.79)(137.9)

3000(20.68)(206.8)

1000(6.89)(68.9)

4000(27.58)(275.8)

5000(34.47)(344.7)

6000(41.37)(413.7)

7000(48.26)(482.6)


FIG. 40

0

50(189)

100(379)

150(568)

200(757)

250(946)

300(1136)

0

A B C D E

2000(13.79)(137.9)

3000(20.68)(206.8)

1000(6.89)(68.9)

4000(27.58)(275.8)

4500(31.03)(310.3)

5000(34.47)(344.7)

1500(10.34)(103.4)

2500(17.24)(172.4)

500(3.45)(34.5)

3500(24.13)(241.3)




Dimensions

52 3A4019H


FIG. 41

0

50(189)

100(379)

150(568)

200(757)

250(946)

300(1136)

350(1325)

400(1514)

0 500(3.45)(34.5)

1000(6.89)(68.9)

1500(10.34)(103.4)

2000(13.79)(137.9)

2500(17.24)(172.4)

3000(20.68)(206.8)

3500(24.13)(241.3)

A B C D E



Dimensions

3A4019H 53

Air/Gas ConsumptionThe air/gas consumption rate depends on the cycle rate of the pump. To estimate your cycle rate, see the Baseline Chemical Dosage Settings, page 16, and the Performance Charts, starting on page 44.

CPM

2.5 in. Motor

Air or Gas Consumption

SCFM (SM3/hr)

15 PSI 25 PSI 50 PSI 75 PSI 100 PSI

10 0.3 (0.5) 0.4 (0.4) 0.6 (1.0) 0.8 (1.4) 1.1 (1.8)

20 0.6 (0.9) 0.7 (1.2) 1.2 (2.3) 1.7 (2.8) 2.1 (3.6)

30 0.8 (1.1) 1.1 (1.9) 1.8 (3.0) 2.5 (4.2) 3.2 (5.4)

40 1.1 (1.9) 1.5 (2.5) 2.4 (4.1) 3.3 (5.6) 4.3 (7.2)

50 1.4 (2.4) 1.8 (3.1) 3.0 (5.1) 4.2 (7.1) 5.3 (9.0)

60 1.7 (2.8) 2.2 (3.7) 3.6 (6.1) 5.0 (8.5) 6.4 (10.9)

70 1.9 (3.3) 2.6 (4.3) 4.2 (7.1) 5.8 (9.9) 7.5 (12.7)

80 2.2 (3.8) 2.9 (4.9) 4.8 (8.1) 6.7 (11.3) 8.5 (14.5)

90 2.5 (4.2) 3.3 (5.7) 5.4 (9.1) 7.5 (12.7) 9.6 (16.3)

100 2.8 (4.7) 3.6 (6.2) 6.0 (10.2) 8.3 (14.1) 10.7 (18.1)

CPM

3.5 in. Motor


SCFM (SM3/hr)


10 0.3 (0.5) 0.4 (0.7) 0.7 (1.2) 1.0 (1.6) 1.2 (2.1)

20 0.6 (1.1) 0.8 (1.4) 1.4 (2.3) 1.9 (3.3) 2.5 (4.2)

30 1.0 (1.6) 1.3 (2.2) 2.1 (3.5) 2.9 (4.9) 3.7 (6.3)

40 1.3 (2.2) 1.7 (2.9) 2.8 (4.7) 3.8 (6.5) 4.9 (8.4)

50 1.6 (2.7) 2.1 (3.6) 3.5 (5.9) 4.8 (8.2) 6.2 (10.4)

60 1.9 (3.3) 2.5 (4.2) 4.1 (7.0) 5.8 (9.8) 7.4 (12.5)

70 2.2 (3.8) 2.9 (5.0) 4.8 (8.2) 6.7 (11.4) 8.6 (14.6)

80 2.6 (4.3) 3.4 (5.7) 5.5 (9.4) 7.7 (13.0) 9.8 (16.7)

90 2.9 (4.9) 3.8 (6.4) 6.2 (10.6) 8.6 (14.7) 11.1 (18.8)

100 3.2 (5.4) 4.2 (7.1) 6.9 (11.7) 9.6 (16.3) 12.3 (20.9)

CPM

4.5 in. Motor


SCFM (SM3/hr)


10 0.5 (0.9) 0.7 (1.2) 1.1 (1.9) 1.6 (2.7) 2.0 (3.5)

20 1.1 (1.8) 1.4 (2.4) 2.3 (3.9) 3.2 (5.4) 4.1 (6.9)

30 1.6 (2.7) 2.1 (3.5) 3.4 (5.8) 4.8 (8.1) 6.1 (10.4)

40 2.1 (3.6) 2.8 (4.7) 4.6 (7.8) 6.3 (10.8) 8.1 (13.8)

50 2.6 (4.5) 3.5 (5.9) 5.7 (9.7) 7.9 (13.5) 10.2 (17.3)

60 3.2 (5.4) 4.2 (7.1) 6.8 (11.6) 9.5 (16.2) 12.2 (20.7)

70 3.7 (6.3) 4.9 (8.3) 8.0 (13.6) 11.1 (18.9) 14.2 (24.2)

80 4.2 (7.2) 5.6 (9.4) 9.1 (15.5) 12.7 (21.6) 16.3 (27.6)

90 4.8 (8.1) 6.2 (10.6) 10.3 (17.4) 14.3 (24.3) 18.3 (31.1)

100 5.3 (9.0) 6.9 (11.8) 11.4 (19.4) 15.9 (27.0) 20.3 (34.5)

Technical Data

54 3A4019H

Technical Data

* Sound Power at 70 psi (0.48 MPa, 4.8 bar), 80 cpm. Sound power measured per ISO-9614-2.

** Sound Pressure was test 3.28 feet (1 m) from equipment.

Python XL Chemical Injection PumpUS Metric

Maximum pneumatic inlet pressure See Models on page 3.Maximum fluid working pressure See Models on page 3.Maximum cycle rate 100 cpmEnvironmental temperature range -40°–176°F -40°–80°CNoise (dBa)2.5 in. Air Motor Sound Power* 83.2 dBA2.5 in. Air Motor Sound Pressure** 76.5 dBA3.5 in. Air Motor Sound Power* 84.5 dBA3.5 in. Air Motor Sound Pressure** 77.9 dBA4.5 in. Air Motor Sound Power* 80.1 dBA4.5 in. Air Motor Sound Pressure** 70.2 dBAInlet/Outlet SizesFluid inlet size 1/4 in. npt(f)Fluid outlet size (3/8 in., 1/2 in., 5/8 in., and 3/4 in. plungers only)

1/4 in. npt(f)

Fluid outlet size (1/4 in. plungers only) HiP HF4Prime/bleed size (3/8 in., 1/2 in., 5/8 in., and 3/4 in. plungers only)

10-32 UNF

Prime/bleed size (1/4 in. plungers only) 1/16 in. npt(f)Pneumatic inlet size 1/4 in. npt(f)Exhaust fitting size 3/8 in. npt(f)Materials of Construction

Pump/Check Valve Seal MaterialSee Configuration Chart on page 4 for seal material. All

other packing materials are PEEK and PTFE unless other-wise noted.

Wetted PartsSee Configuration Chart on page 4 for plunger material. All

other materials are 316 stainless steel unless otherwise noted.

Weight2.5 in. (ALL MODELS) 14.5 lbs. 6.6 kg3.5 in. (ALL MODELS) 20.0 lbs. 9.1 kg4.5 in. (ALL MODELS) 24.5 lbs. 11.1 kg

California Proposition 65

3A4019H 55

California Proposition 65

CALIFORNIA RESIDENTS

WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov.

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 3A4019Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USACopyright 2016, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.comRevision H, May 2020

Graco Standard WarrantyGraco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERSThe Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco InformationFor the latest information about Graco products, visit www.graco.com.

For patent information, see www.graco.com/patents.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-350

http://www.graco.com

www.graco.com/patents

Documents

Instructions-Parts Python XL Chemical Injection